Artificial stone floor and method of making it



Patented July 31, 1934 PATENT OFFICE UNITED STATES Edwin J. Milbum,

Chicago, Ill., assignor to Na tional Floor Company,

Chicago, 111., a copartnership consisting of Arthur E. Burk, Ed win J. Milburn, and John A. Nolan No Drawing. Application"ctober 31, 1931; Serial No. 572,445

'1 Claims.

This invention relates in general to an artificial stone composition adapted to be cast and molded in blocks and other forms and more particularly described for use as flooring, and to the method of making a flooring or other articles of the material.

One of the principal objects of the invention 3' is to produce a new and improved artificial stone ,particularly for flooring which is fireproof, waterprqof, acid-proof and extremely hard when set so that it has a very durable wearing quality.

Another object of the invention is in the provision of an artificial stone material which is easily :shaped and cut, as with an ordinary saw, and into which nails and other fastening devices may be driven or inserted, without cracking the material.

.aAnother object of the invention is in the provi- .sion of an improved flooring material which may be cast in blocks and cut to shape for the purg1 ;pose of forming designs in color, or to cast the material in a continuous slab, either form of which will harden quickly and smoothly and may be smoothed, sanded or polished, as desired.

In carrying out the invention some of the 235 gredients are thoroughly mixed together dly, and

other ingredients are mixed to produce a wet mixture, and these :two mixtures are then mixed together and applied'to the surface to be covered.

cover a surface of approximately fifty-five 36 "to sixty square feet with a layer one inch thick,

the following ingredients are used; using the volume displaced by one hundred pounds of calcined magnesite as a measure, thoroughly mix together the following ingredients producing a 35 dry mixture;

One part calcined magnesite,

Two parts of mill run maple sawdust,

C ne-half part of fine limestone screenings,

Three gallon measure of fine talc.

40 Mix together the following ingredients ing a wet mixture;

To one hundred pounds or one part of magnesium chloride, on a 60 Baum hydrometer for heavy liquids; after the desired liquid is ebtained, add one and one-half gallons of clear emulsified asphalt and mix the ingredients until they are thoroughly dissolved.

When the liquid mixture is added to the dry mixture the result and mix is thoroughly agitated and intermingled until it attains the consistency of mortar, and then one and one-half gallons of paraffin oil are added to the mixture and thoroughly intermingled and the entire mixture is applied to the floor or other surface to be covered immediately.

produc- The hardness to which the material sets is governed by the strength of the chloride solution which is preferably 18 to 20 for use on a wood base and 20 to 22 if used on a concrete base.

The color of the sawdust afiects the color of the composition, maple sawdust producing a composition of lighter appearance than oak sawdust.

In applying the material to a floor or other surface, all dirt, grease, and oil is removed until the surface is thoroughly clean and a bonding coat p5 composed of the chloride solution and magnesite, mixed to produce a thin paste, is applied thereto. If the sub-surface is of stone or concrete, it is preferable to chip the floor at regular intervals and to apply the bonding coat for attaching {ID the mixture to it. 7

In applying the mixture, it is smoothed in place like mortar and may be lightly tamped and leveled with a straight edge and after it has begun to set it is troweled to a desired finish and then al- 475 lowed to harden or set. The setting time is usually from one to three hours, depending upon the temperature conditions.

In further finishing a floor or other surface of this material, it may be sanded, ground and pol- .180 ished to a very smooth finish and the surface may be waxed. To produce the best results the sanding or finishing should be done within two days of the original installation as the surface becomes very hard. 3

Batches of the material or portions thereof may be colored by adding coloring matter to the mixture and in producing designs in colors, the separate batches or portions of the colors should be hardened separately to produce a clear line of 5,90 division between the colors.

While the above proportions of the ingredients are believed to produce the best results, some modification is possible to meet various conditions without departing from the spirit and 5,95 scope of the invention.

I claim:

1. An artificial stone comprising the reaction products obtained by the intimate mixture of one hundred pounds of calcined magnesite enough sawdust to displace twice the space taken by the magnesite, enough fine stone screenings to displace half of the place taken by the magnesite, one hundred pounds of magnesium chloride, one and one-half gallons of emulsified aspha1t,;l05 and sufficient water to make a mixture of the consistency of soft mortar.

2. An artificial stone composition comprising the reaction products obtained by the intimate admixture of the following wet and dry mixtures;-;

by the magnesite and a three thedry mixture comprising one hundred pounds of-calcined magnesite, enough sawdust to dis-' place twice the place taken by the magnesite, enoughlimestone screenings to displace half of the place takenby the "magnesitegand three gallons of fine talc; and the wet mixture comprising,

one hundred pounds of magnesium chloride, enough water to make a mixture of a density-of about Baum, and one and one-half gallons of emulsified asphalt; the parenting intimately mixed together and allowed to harden or set.

3. An artificial waterproof-stone composition to produce approximatelyfiftyffive to sixty'square feet, one inch in thicknessand'comprisingfa mixfture of one hundred pounds of screenings to displace one-half the space'taken gallon measiiremr ns talc .QUQI BK QE QE QRQQ q cvm ch10- ;ridezo eand.cn zha iea l p e r emulsified as t, me. and erh ll d paraffihibil and enough i, ter to make a mixture of the consistency-ofsoitinortar. I I

.. 51 The; method of making a composition of matter which consists (l)- inmixing magnesium .chloride-to a density oi I8 to 212 degreesrBaum; Y

(2 adding and mixing therein one and one-half 0 gallonsofclear emulsified asphalt until it is thor- 9ugh1y dissolved; 3 adding slowly and" Itherei'n a previously mixed dry. mixture comprising; one; hundred pounds of calcined magnesite; .enough sagwc lust todisplace twice the space taken theimag nesitefenough stone screenings toldisplace on'ehalf of thespace takenby the magnesite; andlthree gallons of fine talcgfl) in adding one; and one-half gallons of pariaffin oil to the inixture thus produced and mixiiigiallthe ingrefdientsflthoroughly together; and (5) in applying ,thebrhixture'foflthe consistency of soft mortar to thefloor orother surface to be covered and allowing the'mixture jto set.

5. The method. of'makingfan'artificial stone f 1" one-half gallons of it-is dissolved;' (3) in thoroughly mixing the wet calcined magne site, enough sawdust to displacetwiceithe:spacej taken by the magnesite, enough fine limestone? the surface, with a straight edge 3 d. trowel, in allowing the mixture't'o set; and in grindingalid "surface and "(2) .slushing' it with 'a bondingsoluj plying thereto a Iriixture'for the 'c'onsistencyf or soft mortar consisting ofcalcined magnesitasawcor'dance with claim-5j I s I mixture to the'de'sired thicknessfa-nd allow i lO i h thesurfm .3 Q

composition which consists (1) in preparing a dry mixture consisting of one hundred pounds of calcined magnesite; enough sawdust to displace twice the space taken by the-magnesite;}enough" finestone screenings to displace one-half the of fine talc; (2) in'making a wet mixture consisting of one hundredpounds of magnesium chlo:

ride, enough waterto produce a wet mixture of it}; to 22fBaumjand in adding thereto one and clear emulsified asphalt until anddry'mixture's until they attain the consistencyof softlrnortar; "(4)'{in then adding to the mixture one aridone-half gallons of parafiin oil andthoroughly iigtherein; and (5) inapplying the :miXture to the liner or other surface to be covered and allowing the mixture to set, V a 6. The method of making an artificial waterproof. flooring, l of v a ,Wet and dry mixture ,as set forth 'in claim .15, and 'in "adding, thereto an oil having a parafi'in'ba'se'gfinjapplying'the mixture' to a surfacesto be covere in leveling or smoothing polishing the surface of the set mixture.

7. 'I'hem'ethod' of applying an artificial stone coating to fioororother surface to be'covered which consists in (1') chipping or 'sca trifying the tion made up by mixingtogether calcined magne site, magnesium chloride and water until the I mixt re lattains'a'pastyiconsistency; (3-)- ma -J dust, stone; screenings, -talc,'; magnesium chloride,

to set; and (5) insandingg' grindingfwax .space taken by the magnesite; and three gallons I 

